Packaging assembly for light bulbs, such as led light bulbs, and similar devices

ABSTRACT

A packaging assembly for packaging a light bulb device. The packaging assembly includes a package and a flexible ribbon. The package is sized and shape in accordance with a size and shape of at least one light bulb device. The flexible ribbon extends from the package and displays product information. In some embodiments, the package has a clamshell-like design, including first and second packaging sections connected at a hinge. In other embodiments, the package forms a first hanger hole and the ribbon forms a second hanger hole.

CROSS REFERENCE TO RELATED APPLICATIONS

This Non-Provisional patent application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/817,235, filed Apr. 29, 2013, entitled “PACKAGING ASSEMBLY FOR LIGHT BULBS, SUCH AS LED LIGHT BULBS, AND SIMILAR DEVICES,” the entire teachings of which are herein incorporated by reference.

BACKGROUND

The present disclosure relates to consumer product packaging, shipping and retail display. More particularly it relates to packaging and display assemblies for light bulb-shaped products, such as LED-based light bulb products, and other irregularly shaped items.

Conventional packaging for individual or multiple incandescent (and other format) light bulbs entails a corrugated paperboard or similar material box-like structure within which the light bulb(s) is frictionally held. The paperboard protects the light bulb(s) from damage during shipping and handling, and provides a convenient surface for displaying product information and other graphics/labels. While well-accepted, the box-like shape occupies a volume much larger than the light bulb(s) itself, and thus wastes valuable retail space and resources.

In light of the above, a need exists for improved light bulb (and other product) packaging and display assemblies and schemes.

SUMMARY

Some aspects of the present disclosure are directed to a packaging assembly for packaging a light bulb device. The packaging assembly includes a package and a flexible ribbon. The package is sized and shaped in accordance with a size and shape of the light bulb device. The flexible ribbon extends from the package and displays product information. In some embodiments, the package has a clamshell-like design, including first and second packaging sections connected at a hinge. In other embodiments, the package forms a first hanger hole and the ribbon forms a second hanger hole. With these constructions, the packaging assembly can be loaded to a display rod for, retail sale at either hanger hole, facilitating a compact, nested, side-by-side arrangement, can promote shipping of more product in a typical shipping container, and maximizes viewing of the product by a potential customer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front plan view of a light bulb device packaging assembly in accordance with principles of the present disclosure;

FIG. 1B is a side plan view of the assembly of FIG. 1A;

FIG. 1C is an enlarged view of a portion of a ribbon of the assembly of FIG. 1A;

FIG. 2 is a perspective view of a non-limiting example of a light bulb device that can be contained, shipped and displayed within packaging assemblies of the present disclosure;

FIG. 3 illustrates in simplified form a series of packaging assemblies of the present disclosure compactly arranged along a display rod along with other optional features provided with the packaging assemblies of the present disclosure;

FIG. 4A is a side view of a series of packaging assemblies of the present disclosure compactly arranged along a display rod;

FIG. 4B is a top view of the arrangement of FIG. 4A;

FIG. 4C is an enlarged, front perspective view of a portion of the arrangement of FIG. 4A; and

FIG. 5 is a front view of another packaging assembly in accordance with principles of the present disclosure.

DETAILED DESCRIPTION

One embodiment of a light bulb packaging assembly 20 in accordance with principles of the present disclosure is shown in FIGS. 1A and 1B. The packaging assembly 20 includes a package 22 and a flexible ribbon 24. Details on the various components are provided below. In general terms and as a point of reference, the packaging assembly 20 is useful for maintaining a light bulb (or similarly shaped device) during shipping to a retailer, as well as display at the retailer's location. One non-limiting example of a light bulb device 26 useful with the packaging assemblies of the present disclosure is shown in FIG. 2. In some embodiments, the light bulb device 26 is an LED-based light bulb that is sized and shaped akin to a conventional incandescent (A-19) light bulb, having a bulbous portion 28 and a socket portion 30. As described below, optional features provided with the package 22 correspond with features provided with the exemplary non-limiting light bulb device 26. It will be expressly understood, however, that the packaging assemblies of the present disclosure are not limited to the bulb device 26 of FIG. 2. Regardless, the package 22 is sized to receive the light bulb device 26, and mimics a shape of the light bulb device 26. The flexible ribbon 24 is attached to package 22 and provides a surface for displaying information. Further, the package 22 and the ribbon 24 can each incorporate one or more features that facilitate displaying of the packaging assembly 20 (including the light bulb device 26 held within the package 22) at a retail location, with multiple ones of the loaded packaging assemblies 20 being compactly arranged along a conventional display rod.

As best reflected in FIG. 1B, the package 22 can be a thin-walled plastic body defining first and second packaging sections 40, 42. In some embodiments, the package 22 body is a homogenous, integral structure, with the packaging sections 40, 42 being connected at a first end 44. The first end 44 serves as a hinge (e.g., a living hinge), with the packaging sections 40, 42 being pivotable away from one another at the second, opposite end 46 (pivoting at the first end 44) in forming a clamshell packaging arrangement. The plastic body of the package 22 can be a transparent or substantially transparent polymer (e.g., at least 90% transparent) such that a potential consumer can readily view a light bulb device maintained within the package 22. In some embodiments, the package 22 is formed from recycled and/or recyclable plastic. As a point of reference, the substantially transparent nature of the package 22 in accordance with some embodiments of the present disclosure is reflected by the illustrations of FIGS. 1A and 1B, with optional surface features provided along the sections 40, 42 (e.g., the optional ribs or dimples described below) being visible “through” the plastic package 22.

Each section 40, 42 has a perimeter region 50 and a central region 52. A combined size and shape of the central region 52 corresponds with a size, shape, and surface contours of the light bulb device 26 such that the light bulb device 26 can be compactly received within and maintained by a combination of the central regions 52 of the sections 40, 42. For example, the central regions 52 each have a bulbous area 54 the combined size and shape of which mimics the size and shape of the bulbous portion 28 of the light bulb device 26 to be packaged. Similarly, the central regions 52 each have a socket area 56 that mimics the socket portion 30. The perimeter regions 50 can be flat.

In some embodiments, the packaging sections 40, 42 include or define optional ribs 60 along the corresponding central regions 52. Where provided, the ribs 60 correspond with features optionally included with the light bulb device 26 to be packaged. For example, with the non-limiting exemplary light bulb device 26 of FIG. 2, slots 62 are formed (e.g., by finned heat sinks included with the light bulb device 26). The ribs 60 are sized and shaped to nest with corresponding ones of the slots 62, serving to orient the light bulb device 26 relative to the package 22 as desired, and limit possible movement of the light bulb device 26 relative to the package 22. Other product orienting features can be employed in place of the ribs 60. In yet other, related embodiments, the central regions 52 optionally form or define display dimples 64 (FIG. 3). The dimples 64 can be formed as inward projections optionally configured to bear or abut against a surface of the light bulb device 26 (or other product) within the package 22; by providing the dimples 64 along both of the opposing packaging sections 40, 42, the light bulb device 26 can optionally be more firmly held within the package 22. In other embodiments, a location of the dimples 64 along the bulbous area 54 corresponds with a spatial location of the socket area 56 relative to a length of the ribbon 24 (and/or a spatial location of the socket area 56 relative to features formed along a length of the ribbon 24) as described below. In yet other embodiments, the packaging 22 is configured for packaging an LED light bulb device that has a smooth, continuous bulbous portion (e.g., does not include metal heat sinks on an exterior of the bulbous portion 28) such that the ribs 60 (or similar features) are omitted.

The first and second packaging sections 40, 42 combine to define a retention zone 70 adjacent the first end 44 (i.e., the retention zone 70 is apart from the central regions 50). The retention zone 70 includes or forms a hanger hole 72 (e.g., each of the packaging sections 40, 42 forms a hole that, upon final assembly, are aligned with one another to define the continuous hanger hole 72). The hanger hole 72 can have various shapes and sizes, and is generally configured to receive a rod-type hanger conventionally employed for retail display.

The retention zone 70 is further configured to receive the flexible ribbon 24. For example, a slot 74 (referenced generally) is provided, and is sized and shaped for passage of the ribbon 24. In other embodiments, the package 22 can be molded or otherwise formed about the flexible ribbon 24.

The flexible ribbon 24 can assume a variety of forms, and in some embodiments is a ribbon-like material (e.g., a thin polymer or paper-based material with minimal lengthwise rigidity) having a surface conducive to displaying indicia or information (words, numbers, characters, pictures, bar codes, or other indicia). The indicia can be directly printed on to surfaces of the ribbon 24 (e.g., front surface 80 visible in FIG. 1A and/or back surface opposite the front surface 80) and/or one or more labels carrying desired information can be applied to surfaces of the ribbon 24. In some embodiments, the ribbon 24 can be formed to define segments 82 separated by a fold line 84. Each segment 82 can be optionally be designated (e.g., sized and shaped) to display predetermined indicia (such as a bar code) as generally reflected in FIG. 1C. FIG. 1C further reflects that the fold lines 84 can have a hinged configuration.

The flexible ribbon 24 further defines one or more hanger holes 86. The hanger hole(s) 86 can have various shapes and sizes, and is generally configured to receive a rod-type hanger conventionally employed for retail display.

With the above construction, all desired information, bar codes, pictures, instructions, etc., of interest can be displayed on the flexible ribbon 24, with the package 22 being substantially clear or transparent so that a potential purchaser can easily view the contained light bulb device. Further, the multiple hanger holes 72, 86 promote a compact retail display arrangement. For example, FIG. 3 illustrates three of the packaging assemblies 20A-20C at a retail location, connected to a display rod 100 and thus available for consumer viewing and selection. As a point of reference, when packaged with the light bulb device 26 (or other product), the packaging assembly 20 and the light bulb device 26 combined to device a packaged good article or a “packaged light bulb”. The display rod 100 can be a conventional display rod, and is mounted to a wall (not shown) in any manner known. The first or front-most packaging assembly 20A is connected to the display rod 100 via the hanger hole 72 (referenced generally) in the corresponding package 22A. The second or sequentially next packaging assembly 20B is connected to the display rod 100 via the hanger hole 86 (referenced generally) in the corresponding ribbon 24B. Because the first packaging assembly 20A is hanging from the package 22A and the second packaging assembly 20B is hanging from the ribbon 22B, the package 22B of the second packaging assembly 20B is below the package 22A of the first packaging assembly 20A. As a result, the bulbous area 54 of the second packaging assembly 20B is offset from the bulbous area 54 of the first packaging assembly 20A, allowing the first and second packaging assemblies 20A, 20B to be compactly arranged relative to one another (i.e., as compared to an arrangement where the bulbous areas 54 were aligned/in contact with one another). A similar, compact arrangement is provided between the second and third packaging assemblies 20B, 20C (with the third packaging assembly 20C being connected to the display rod 100 at the hanger hole 72 of the corresponding package 22C). FIGS. 4A-4C provide additional examples of packaging assemblies of the present disclosure being connected to a display rod.

FIG. 3 further illustrates an optional enhancement to the compact display arrangement, with the packages 22 each incorporating the optional dimples 64 that nest with one another in the alternating hanger hole connection locations described above. For example, with the first and third packaging assemblies 20A, 20B mounted to the rod 100 at the corresponding package 22 and the second packaging assembly 20B mounted to the rod 100 at the corresponding ribbon 24, the socket area 56 of the first packaging assembly 20A nests within one of the dimples 64 of the second packaging assembly 20B; similarly, the socket area 56 of the third packaging assembly 20C nests within another one of the dimples 64 of the second packaging assembly 20B.

Due to the flexible construction, the ribbon 24 of the packaging assembly 20 freely “drops” in the display state of FIG. 3 (when the packaging assembly 20 is connected to the display rod 100 at the hanger hole 72 of the corresponding package 22 as shown for the first packaging assembly 20A in FIG. 3). A potential purchaser can remove the first or front-most packaging assembly 20A from the display rod 100 and quick review all information of interest as presented by the ribbon 24. Further, any other information of interest to the retailer (e.g., bar codes) can be displayed on the ribbon 24.

In addition to promoting the compact display arrangements described above, the packaging assemblies of the present disclosure occupy less shipping space as compared to conventional light bulb packaging designs. Multiple ones of the packaging assemblies (previously packaged with the corresponding product, such as the light bulb device described above) are placed into a common shipping box for delivery to the retailer. In this regard, a shape of the shipping box can closely conform to a footprint of the package 22 alone (and thus of the light bulb device packaged therein); the ribbons 24 readily collapse down into the shipping box.

The packaging assemblies of the present disclosure provide a marked improvement over previous designs and in some embodiments build upon the attributes embodied by recently available LED-based light bulb devices that utilize a durable (e.g., polycarbonate) enclosure; these bulb enclosures are quite durable and provide support to the packaging itself. The close-offset package protects the light bulb device from abrasion during transport. Another embodiment of a packaging assembly 200 in accordance with principles of the present disclosure is shown in FIG. 5 (without the flexible ribbon described above that may optionally be included).

All the writing required on the package is remote from the product by printing on a flexible ribbon-like material extending from the package. This printing can be on both sides of the ribbon as desired. The entire packaged light bulb device is viewable by a potential customer unlike conventional light bulb packaging.

The light bulb device is well centered in the package, optionally making use of the heat sink (or other features) provided with the light bulb device being packaged. This can further serve to orient the product as displayed.

The printed ribbon collapses and packs in the shipping box permitting the bulbs to stack end-to-end and in offset rows for a most compact solution. Considerably more bulbs fit into a typical bulb shipping box compared with other packaging systems. It is estimated that the packaging assemblies of the present disclosure can facilitate containment of in upwards of 97,200 packaged light bulb devices in a 40 foot shipping container. Similar efficiencies carry over to trucking, distribution storage and store display space savings.

The package has a hanger hole at the top, and the printed ribbon can also have a hanger hole, allowing a rod hanger display to partially nest adjacent packaged bulbs. In other words, every other packaged light bulb device can be hung high or low to nest the shapes of the packaged light bulb devices while displaying them upright. The ribbon simply drops or flops to the side of the hanger rod.

The entire packaging assembly can be made of recyclable material. Further, the molded package and the ribbon can be manufactured and/or handled by advanced automation.

Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present disclosure. 

What is claimed is:
 1. A packaging assembly for packaging a light bulb device, the packaging assembly comprising: a package sized and shaped in accordance with a size and shape of the light bulb device; and a flexible ribbon extending from the package and displaying product information.
 2. The packaging assembly of claim 1, wherein the package includes first and second packaging sections connected at a hinge.
 3. The packaging assembly of claim 2, wherein the packaging sections are connected at a first end of the package, the first end being opposite a second end, and further wherein the ribbon extends from the first end.
 4. The packaging assembly of claim 3, wherein the first and second packaging sections combine to define a retention zone adjacent the first end, and further wherein the retention zone forms a first hanger hole.
 5. The packaging assembly of claim 4, wherein the ribbon forms a second hanger hole.
 6. The packaging assembly of claim 4, wherein the retention zone further forms a slot for receiving the ribbon.
 7. The packaging assembly of claim 1, wherein the ribbon forms a plurality of segments each separated by a fold line.
 8. The packaging assembly of claim 7, wherein each of the segments forms a hanger hole.
 9. The packaging assembly of claim 8, wherein at least one of the segments displays a bar code.
 10. The packaging assembly of claim 1, wherein the package is configured to contain a plurality of light bulb devices.
 11. A method of displaying packaged light bulbs for retail sale, the method comprising: receiving first and second packaged light bulbs each including: a light bulb, a package sized and shaped in accordance with a size and shape of the light bulb, wherein the light bulb is stored within the package, the package forming a first hanger hole, a flexible ribbon extending from the package; mounting the first packaged light bulb on a display rod at a retail location, including inserting the first hanger hole of the first packaged light bulb over the display rod; and mounting the second packaged light bulb on the display rod, including inserting the second hanger hole of the second packaged light bulb over the display rod.
 12. The method of claim 11, wherein the package of each of the first and second packaged light bulbs defines a bulbous area and a socket area, and further wherein following the steps of mounting the first and second packaged light bulbs on the display rod, the socket area of the first packaged light bulb nests within the bulbous area of the second packaged light bulb.
 13. The method of claim 11, further comprising: receiving third and fourth packaged light bulbs each including the light bulb, the package and the flexible ribbon; and following the step of mounting the second packaged light bulb on the display rod, the method comprising: mounting the third packaged light bulb on the display rod, including inserting the first hanger hole of the third packaged light bulb over the display rod, mounting the fourth packaged light bulb on the display rod, including inserting the second hanger hole of the fourth packaged light bulb over the display rod.
 14. The method of claim 11, wherein the step of mounting the first packaged light bulb includes folding the ribbon of the first package light bulb onto the package of the first packaged light bulb.
 15. A packaged good article comprising: a light bulb device having an outer shape defining a bulbous region and a socket region; and a packaging assembly comprising: a package sized and shaped in accordance with the outer shape of the light bulb device, the package including a bulbous area corresponding with the bulbous region and a socket area corresponding with the socket region, a flexible ribbon extending from the package and displaying product information; wherein the light bulb device is stored within the package. 